Shovel Open Gear Inspection SOP



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|SOP: Shovel Open Gear Lubrication Inspection |DATE |( NEW | |

| |4/28/2011 |REVISED |PAGE 1 of 3 |

| | |___ Number | |

|TYPICAL CUSTOMERS |WORK TYPE |WORK ACTIVITY (Description) |

|Mining, Construction |Shovel inspection |Grease film inspection, Auto-lube system efficiency, contamination control, |

| | |gearing inspection |

|DEVELOPMENT TEAM |POSITION / TITLE |REVIEWED BY/DATE |POSITION / TITLE |

|Maurice Dionne |Sr. Lube Engineer |Raymond Sauvé 6/1/2011 |FES Advisor |

|Gaetan Lacasse |Sr. Lube Engineer |Tom Schiff 10/24/2012 |FES Manager |

|Juan Otero |Lube Engineer | | |

|PLEASE UTLIZE ATTCHED GENERAL JSA AS GUIDANCE AND, any SITE SPECIFIC JSAs that are available. |

|PLEASE ASSESS YOUR OWN CONDITIONS OR SPECIFIC SAFETY REQUIRMENTS AND BE SAFE. |

|Example Mine Site Access JSA : |

|EQUIPMENT INDEPENDENT OF JSA DESIRED DOCUMENTATION |

| CLIPBOARD OR TABLET PC CRESCENT WRENCH | DAY OF - ENGINEERING SERVICE NOTICE (ESN) AS LEAVE BEHIND |

|IR GUN SCREWDRIVER'S |FINAL - ENGINEERING SERVICE REPORT (ESR) WITH TOTAL COST of OWNERSHIP (TCO) |

|FLASHLIGHT ELEC. BLACK TAPE |SAVINGS |

|SAMPLE THIEF, BOTTLES & LABELS |OTHER (SPECIFY) |

|RAGS |SHOVEL INSPECTION CHECKLIST |

|CAMERA - PERMIT MIGHT BE REQUIRED? CHECK WITH CUSTOMER |COLD PERMIT FORM |

|IF IT'S OK TO USE YOUR OWN TOOLS OR THEY SUPPLY, SUCH AS LADDER, ETC.. |FIELD LEVEL ASSESSMENT FORM |

|TIME ESTIMATED TO COMPLETE THIS TASK NUMBER OF PEOPLE TO PERFORM THIS TASK |

|15 to 60 MINUTES PER SHOVEL DEPENDING ON COMPLEXITY |1 -2 |

|FREQUENCY TO PERFORM THIS TASK SKLLS REQUIREED TO PERFORM THIS TASK |

|DEPENDS ON CUSTOMER COMMITMENT, USUALLY 1 - 2 TIMES PER YEAR | MECHANICAL APPTITUDE |

| |OPEN GEAR LUBE APPLICATION "BEST PRACTICES " |

| |KNOWLEDGE OF GREASE COVERAGE - RICH OR LEAN |

| |KNOWLEDGE OF LUBE SYSTEMS IN ORDER TO IDENTIFY LEAKY GREASE LINES, FAULTY |

| |INJECTORS, MIS-ALIGNED DRIP TUBES, |

| |FAULTY SPRAY NOZZLES |

|JOB COMPETANCIES REQUIRED TO PERFORM THIS TASK, |TRAINING REQUIRED TO PERFORM THIS TASK |

|PRODUCT SELECTION - OPEN GEAR LUBRICANT. | lms - FUNDAMENTAL OF LUBRICATION - VOL 1.0 - 7.0 eLEARN |

|OFFER EXECUTION - BASIC OFFER EXECTUION - INSPECTIONS - OPEN GEAR LUBE KNOWLEDGE |lms - LUBRIZOL INDUSTRIAL OIL & GREASE eLEARN |

|INDUSTRIES - MINING ELECTROMECHANICAL AND HYDRAULIC SHOVELS |lms – WHMIS (Workplace Hazardous Materials Information System) |

| |lms – PVMG (Passenger & Service Vehicle Safety Management Guide Training |

| |FALL ARREST - if working over 6 feet |

| |Inside Sales - TECHNICAL RESOURCES - CENTRAL LUBE SYSTEMS |

| |Inside Sales - TECHNICAL RESOURCES - OPEN GEAR LUBE |

| |SITE SPECIFIC ORIENTATION SAFETY TRAINING |

| |CSTS - (CONSTRUCTION SAFETY TRAINING SYSTEM) If required |

PURPOSE - To describe the process of conducting a Electromechanical and Hydraulic Shovel Open Gear Inspection while the equipment is shut down (at rest), with the desired reporting that provides the value back to the customer, while supporting the standard Marketing Offer.

|LOCATION |JOB STEPS |

|Mine Area for Equipment to be Inspected |Review JSA for mine entry (general and site specific) and JSA for Shovel Inspection. |

| |Check with operation if equipment to be inspected is available. |

| |If required borrow a radio to communicate with Mine personal and review any safety warnings while on site. |

| |If required fill out a Cold Permit Form (customer specific) and review best route to access the mine to the |

| |equipment to be inspected. |

| |Complete Customer Field Level Assessment (FLA) form with facility mechanics or operators prior commencing |

| |work as required. |

| |Prior entering mine site - request permission from Pit Forman |

| |When authorization is granted proceed to the shovel to be inspected- If not familiar with the area ask to be |

| |escorted. |

| |If the shovel is shut-down for PM, proceed and review FLA with personnel in the area, so they know what you |

| |will be doing. |

| |Use lock out tag out procedure |

| |If you are inspecting the shovel on Coffee break. Wait in a secure area (away for haul trucks) until break |

| |time. |

| |Before approaching the equipment ask permission from the shovel operator if it's safe to approach and park |

| |your vehicle cab side so the operator can see you. Make sure the boarding ladder is down and that the |

| |operator is out of his/her seat to start inspecting the shovel |

|Shovel Inspection |Lube room system check: |

|Use Shovel Inspection form and document |Manually test each grease system |

| |Document any inefficiencies |

| |Check lube room for cleanliness |

| |Document cycle time of each system from the PLC (computer) |

| |Inspection process |

| |Check all major components as outlined on the Shovel Inspection form |

| |Make sure to look for structural damage while on the shovel. Hand rails are not to be trusted. Always make |

| |sure they are secure. |

|Storage and Handling |Observe types of transfer containers for proper oil label |

| |Observe gear boxes for proper labels and document any leaks |

| |Are there competitors product on the shovel - For example OEM compressor oil, coupling and/or electric motor |

| |greases |

| |General note on housekeeping of containers |

|Feedback about this SOP - Send to Field |. |

|Engineering Advisor/Supervisor | |

DOCUMENTING YOUR WORK - The Shovel Inspection is used to verify the performance of Mobil premium and flagship Open Gear and Multi-Purpose grease. The Shovel Inspection Worksheet can be used as a guide to assist in the inspection and preparing an Engineering Service Notice or Engineering Service Report. Proper placement is an Appendix. TCO calculations that may apply are: Expenditures Reduction, Process Improvement, Revenue Enhancement and Asset Improvement as detailed below. The TCO Worksheets are the preferred format to include in your report. Proper placement is an Appendix. Additional guidance will incorporate our messaging of TCO to include Sustainability, Safety and Productivity relationships.

Expenditure Reduction - reduced lubricant consumption costs are the most typical expenditure savings. These only result from the offset of reducing the amount of grease delivered to various components. Lube application intervals from the previous cycle time and decreasing the amount of grease being delivered and in some cases can be as much as 10 to 20% reduction. Expenditures could also be the cost of pump replacement ($2,000 good average cost for 75:1 Lincoln grease pumps), injectors change outs, gearing components, and other grease system components. This may allow the customer to plan for a replacement during a planned outage instead of an emergency shutdown. A third expenditure may come from cleaning costs of removing of grease from over lubed applications. Find out how much the unit cost of disposal is and use the consumption on an annual basis. Make sure to factor in the reduced usage with Dynagear (or premium and flagship) products.

Process Improvement - the hourly wages (including burden) for personnel to perform existing tasks. If pump replacements or lubricant change outs are reduced, use these to determine Process improvements. If lubricant usage is reduced, use the time to handle drums and the time to dispose of used lube to determine Process improvements.

Revenue Enhancement - any serious abnormal grease system component or lubricant condition observed may be repaired during normal maintenance and reduces the potential for downtime. “Unscheduled Downtime”, resulting in lost production and most often, scrapped parts or material. Shovel downtime can equate to several $100K/day. Keep this in mind.

Asset Improvement - use the customers "cost to carry" (usually 20%) inventories. This is used from the Expenditures components for example, if you reduce the quantity of lube needed, take that amount cost and multiply by the "cost to carry" to determine the Asset value.

Refer to Expenditure Reduction, Process Improvement, Revenue Enhancement, Asset Improvement and TCO Summary Worksheet.xls.

Documentation Links:

Inspection Worksheet Report Template TCO - Worksheet FLA

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Link to example ESR

Link to FES Meeting, Shovel Open Gear Inspection Best Practices, (9/2012)

|Safety: Team wearing proper PPE |

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Inspection in progress

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|Sampling contamination |Cleaning swing pinion for inspection |

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|Truck & Shovel |Leakey grease line |

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|Crowd pinion |Crowd pinion - Good drip tubes adjustment |

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| |Ring Gear |

|Swing Pinion | |

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|Don't miss details like broken gear tooth! |Optimized lube coverage |

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Standard Operating Procedure (SOP)

Read all of the steps in this SOP before beginning work. Follow customer labor requirements (eg respect Union work)

Noticed the dozer?

Good Spray Pattern

Sc

Scrapers installed to keep contamination away from the ring gear

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